Reinforced plug

ABSTRACT

A plug for closing a hose connector termination includes a hollow cylindrical body closed by a rounded end portion and open at the opposite end. The plug comprises tensioned fibrous material that extends in a continuous manner across the width of the rounded end and to the sides of the body.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of U.S. patent application Ser. No.13/789,223, filed Mar. 7, 2013, the entire disclosure of which isexpressly incorporated herein by reference.

BACKGROUND

Many vehicles, including semi-tractors, rely on hoses to convey fluidsto and from different parts of the engine's cooling system, brakesystem, lubrication system, hydraulic system, air-conditioning system,and the like. Many of the systems are designed to leave open hoseconnector terminations for future use. In order to prevent fluids frombeing discharged through these extra hose connector terminations, plugsmade of rubber are provided on the terminals. A problem arises sincerubber may deteriorate over a period of time due to thermal cycling andpressure. Alternatively, the extra hose connector terminations have tobe permanently sealed through welding, for example, and the entire partmust be replaced in order to be able to connect a hose at that location.

Accordingly, there is a long-felt need for robust and long-lasting hoseconnector termination plugs.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features ofthe claimed subject matter, nor is it intended to be used as an aid indetermining the scope of the claimed subject matter.

Some embodiments are related to a method of making a reinforced resinplug. The method includes providing a die having a cylindrical bodyterminating in a curved or rounded end, wrapping a fibrous materialaround the die during or while the fibrous material is tensioned,wherein the fibrous material is placed to extend in a continuous manneracross the width of the rounded end of the body and to opposite sides ofthe cylindrical body, applying a curable resin on the die, curing theresin, and removing a reinforced cured resin plug from the die.

In the embodiments related to the method of making a reinforced resinplug, the die may further include a pole connected to the cylindricalbody, wherein the pole extends perpendicular to a longitudinal axis ofthe cylindrical body.

In the embodiments related to the method of making a reinforced resinplug, removing the plug includes cutting the cured fiber-reinforcedresin plug around the circumference of the die on both sides of the poleto produce two reinforced resin plugs.

In the embodiments related to the method of making a reinforced resinplug, the fibrous material can be applied before the curable resin.

In the embodiments related to the method of making a reinforced resinplug, the curable resin can be applied before the fibrous material.

In the embodiments related to the method of making a reinforced resinplug, the curable resin and the fibrous material can be appliedtogether.

In the embodiments related to the method of making a reinforced resinplug, the method may further include tensioning the fibrous materialwhen the fibrous material is applied on the die.

In the embodiments related to the method of making a reinforced resinplug, the fibrous material can include spun filaments.

In the embodiments related to the method of making a reinforced resinplug, the fibrous material can include a continuous filament.

In the embodiments related to the method of making a reinforced resinplug, the fibrous material can be a mesh of interconnected filaments.

In the embodiments related to the method of making a reinforced resinplug, the curable resin can be an elastomer, such as, but not limited tosilicone, ethylene propylene diene monomer, or rubber.

Some embodiments are related to a reinforced plug. The reinforced plugmay include a hollow cylindrical body closed by a rounded end portionand open at the opposite end, wherein the plug comprises tensionedfibrous material that extends in a continuous manner across the width ofthe rounded end and to the sides of the body.

In the embodiments related to the reinforced plug, the fibrous materialmay include a plurality of discrete filaments, at least one or moreextending in a continuous manner across the width of the rounded end andto the sides of the body.

In the embodiments related to the reinforced plug, the fibrous materialmay include a mesh.

In the embodiments related to the reinforced plug, the plug may includemore than one layer, each layer having tensioned fibrous material andresin.

In the embodiments related to the reinforced plug, the plug may includeat least one layer having a cured resin and further includes the fibrousmaterial within the resin.

In the embodiments related to the reinforced plug, the plug may includemore than one layer of cured resin and fibrous material.

Some embodiments are related to a method for closing a conduit connectortermination. The method includes placing a plug made from a reinforcedresin on a conduit connector termination, wherein the plug comprises ahollow cylindrical body closed by a rounded end portion and open at theopposite end, wherein the open end is placed over the conduit connectertermination; placing a clamp on the plug that compresses the plug bodyto the conduit connecter termination, wherein the plug comprises atensioned fibrous material that extends across the width of the roundedend and to the sides of the body in a continuous manner.

In the embodiments related to a method for closing a conduit connectortermination, the pressure inside the conduit connector terminationapplies a force on an inside surface of the rounded end of the plug, andthe force is partly transferred via the fibrous material to a bodyportion being compressed by the clamp, thereby providing for addedstrength.

In the embodiments related to a method for closing a conduit connectortermination, the conduit connector termination can be a hose barb.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated as the same become betterunderstood by reference to the following detailed description, whentaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a diagrammatical illustration of a die for making a reinforcedresin plug;

FIG. 2 is a diagrammatical illustration of a step in a method of makingthe reinforced resin plug;

FIG. 3 is a diagrammatical illustration of a step in a method of makingthe reinforced resin plug;

FIG. 4 is a diagrammatical illustration of a step in a method of makingthe reinforced resin plug;

FIG. 5 is a diagrammatical illustration of a step in a method of makingthe reinforced resin plug;

FIG. 6 is a diagrammatical illustration of a step in a method of makingthe reinforced resin plug;

FIG. 7 is a diagrammatical illustration of a reinforced resin plug;

FIG. 8 is a diagrammatical illustration of a method of closing a conduitconnector termination using a reinforced resin plug;

FIG. 9 is a diagrammatical illustration of a method of closing a conduitconnector termination using a reinforced resin plug;

FIG. 10 is an alternate step of a method for making a reinforced resinplug; and

FIG. 11 is an alternate step in a method for making a reinforced resinplug.

DETAILED DESCRIPTION

Plugs are used to seal the open ends of conduit connector terminationsof vehicles, for example. A conduit connector termination may be abarbed connector termination to which a hose can be connected. The needfor plugs arises out of a desire to have additional conduit connectorterminations for possible future additions to an engine's coolingsystem, brake system, lubrication system, hydraulic system,air-conditioning system, and the like. Typically, these extra conduitconnector terminations are closed off using a rubber plug or even weldedshut. However, rubber has a tendency to degrade over time due to thermaland pressure cycling, and welding creates a need to replace entireparts. Accordingly, this application discloses a plug made from a resinincluding reinforcing fibers. The disclosed plugs can be manufactured ina variety of diameters, lengths, and shapes to provide for the varietyof currently available conduit connector terminations.

Referring to FIGS. 1-6, a method of making a fiber-reinforced resin plugwill now be described. FIG. 1 shows a diagrammatical illustration of adie 100 having a cylindrical body 108 terminating in opposite curved orrounded ends 102 and 104. The die 100 can be solid or hollow. In oneembodiment, the die 100 may include a pole 106 attached perpendicular tothe longitudinal axis of the cylindrical body 108.

The diameter of the die 100 can be slightly smaller than the diameter ofthe conduit connector termination for which the plug is intended. Insome embodiments, the die 100 may be a cylindrical member having twoends. The ends may be flat or the ends may be rounded as shown in thefigures. The die 100 includes an elongated pole 106 attached generallyat the center of the cylindrical body 108 and perpendicular to thecylindrical body 108. The pole 106 is used to support the die 100 duringthe wrapping of fibrous material and coating of the fibrous materialwith the resin. The die 100 may be made of metal, such as stainlesssteel or carbon steel, plastics, or ceramics.

Before using the die in making plugs, the die 100 may be coated with amold release. Suitable mold releases may include, but are not limitedto, fluoropolymers, such as polytetrafluoroethylene (Teflon®),silicone-based oils, and the like.

FIG. 2 shows a step in a method of making a reinforced resin plug. InFIG. 2, one end of a continuous fibrous material 110 may be attached toa starting point 112, such as where the pole 106 connects to thecylindrical body 108. A purpose for rigidly attaching the fibrousmaterial 110 is so that the fibrous material 110 may be tensioned whilebeing applied over the die 100. Tension can refer to a force to stretchthe fibrous material during application or a force that renders thefibrous material 110 taut during the application.

In some embodiments, the fibrous material 110 can be a continuous threadmade from individual staple fibers, such as through twisting orspinning. In some embodiments, the fibrous material 110 can be a singlecontinuous filament such as is typically made from synthetic polymers,such as nylon. In some embodiments, the fibrous material 110 may bewrapped by hand. However, in other embodiments, the fibrous material 110can be wrapped around the die 100 by machine, similar to a windingmachine. With a machine, the fibrous material 110 may be provided on aspool, wherein the spool creates drag upon unwinding, thereby applyingtension as the fibrous material 110 is wrapped around the die 100. Insome embodiments, the fibrous material 110 is wrapped a multiplicity oftimes, such that with each wrap, the fibrous material 110 extends fromone end 102 of the die to the opposite end 104 in a lengthwise fashionor generally along the longitudinal axis. The fibrous material 110 canextend continuously from approximately the center of the die 100, aroundat least one rounded end 102, 104, and extend to the opposite center onthe other side of the die 100. The purpose is to create a multiplicityof filaments that extend from the center of the die on one side, aroundthe end, and to the opposite center side to add strength. In addition tofilaments placed longitudinally on the die 100, filaments of the fibrousmaterial 110 may also be wrapped circumferentially on the die 100.Additionally, filaments of the fibrous material 110 may be wrapped bothcircumferentially and along the length of the die 100. Preferably, thefibrous material 110 is continuous and extends in a continuous mannerand a multiplicity of times on the die 110 from the cylindrical body108, across at least one rounded end 102, 104, and extends back to thecylindrical body 108 on the opposite side. It is desirable that thefibrous material extend from one side of the cylindrical body 108 acrossthe rounded end or ends 102, 104 and back to the cylindrical body 108.In this manner, the plug is able to withstand the forces experienced atthe interior of the rounded end, wherein the fibers act to transfer theforces to the cylindrical body, which can then be clamped to the conduitconnector termination. This allows the load-bearing portions at the endsof the plug to redistribute the forces along reinforcing filaments tothe portion of the plug being held to the conduit connector terminationvia the clamp, as described in more detail below.

Referring to FIG. 3, the fibrous material 110 has been wrapped amultiplicity of times over the die 100. The fibrous material 110 createscontinuous filaments extending at least from one side of the cylindricalbody 108 across the width of at least one rounded end and continues tothe opposite side of the cylindrical body 108. This wrapping ofcontinuous filaments of fibrous material 110 is done a multiplicity oftimes to cover at least one end of the cylindrical body and preferablythe two ends. The covering of the rounded ends 102, 104 with fibrousmaterial 110 may be complete or partial covering.

Referring to FIG. 4, a curable resin 116 is applied onto the die 100over the fibrous material 110. In some embodiments, the resin 116 isapplied after applying the fibrous material 110. In some embodiments,the resin 116 may be applied before applying the fibrous material 110.In some embodiments, the fibrous material 110 and the resin 116 may beapplied together. In the latter case, the resin and fibrous material maybe applied by what are known as pre-preg (pre-impregnated) materials.After applying the resin 116, the resin is allowed to cure. The cure maybe conducted at room temperature or, alternatively, the cure may beartificially accelerated, such as by placing in a heated oven. Suitableresins include elastomers and may include synthetic and natural resins.Elastomers include silicone rubber, butyl rubber, ethylene propylenerubber, ethylene propylene diene rubber, polyisoprene rubber,polybutadiene rubber, nitrile rubber, and the like. The resin 116 mayinclude one or more polymers or monomers, curing agents, or catalysts.The methods of curing or preparing the foregoing resins are known in theart.

Referring to FIG. 5, after sufficient curing has taken place, the curedresin with fibrous material embedded therein may be cutcircumferentially along the cut lines 118 and 120 illustrated in FIG. 5.

Referring to FIG. 6, one plug has been cut along the cut line 118, whichproduces the fiber-reinforced resin plug illustrated in FIG. 7. A secondplug may be produced by cutting along the cut line 120. The materialremaining in the center may be discarded.

Referring to FIG. 7, the plug 122 includes a hollow cylindrical body 130closed by a rounded end portion 124 and open at the opposite end 128.The plug 122 includes tensioned filaments of fibrous material 126 thatextend in a continuous manner from one side of the body 130 across thewidth of the rounded end 124 and to the opposite side of the body 130.The plug 122 may include a multiplicity of filaments that each extendsin a continuous manner from one side of the body across the width of therounded end 124 and to the opposite side of the body 130. The fibrousmaterial 126 may be continuous filaments of synthetic polymers, such asnylon. Alternatively, the fibrous material 126 may be comprised ofindividual discrete fibrils that are twisted or woven into a singlecontinuous thread, such as natural or synthetic fibers. The plug 122 maywithstand an internal pressure of 50 psig or more, for example.

Referring to FIG. 8, a method for closing an open conduit connectortermination is illustrated. The conduit connector termination 132 has anopen end that is desirable to be sealed off to prevent the escape offluids, for example. The conduit connector termination 132 may be a hosebarb including at least one barb 144. The reinforced plug 122 is placedon the conduit connector termination 132. The plug 122 includes a hollowcylindrical body closed by a rounded end portion 124 and open at theopposite end, and the open end is placed over the conduit connectortermination 132. A clamp 142 is placed over the hollow cylindrical bodythat is adjacent to the conduit connector termination 132. In order tobetter seal the conduit connector termination 132 and withstand theinternal pressure, the plug 122 transfers forces 138 experienced at theinterior of the rounded end 124 and transfers those forces 140 along thebody of the plug 122 via the fibrous material 126 to that portion of theplug that is captured by the compressive force applied by the clamp 142.

As illustrated in FIG. 9, a reinforced plug 122 fitted on the end of aconduit connector termination 132 provides a multiplicity of individual,discrete fibrous materials 126 that extend in a continuous manner fromone side of the body 130 of the plug 122, across the width of therounded end 124, and to the opposite side of the body 130. This allowsthe ends of the fibrous material 126 near the opening of the plug to becaptured by the compressive force of the clamp 142 at the cylindricalbody 130. “Continuous” as used herein means having no breaks such thatat least one or more continuous fibrous materials 126 extend from oneside of the hollow body 130 across the width of the rounded end 124 andterminate at another location at the hollow body 130. A fibrous material110 may include fibers made from natural or synthetic fibers. Anycombination of fibers is also possible. Examples of suitable reinforcingfibers include inorganic fibers, such as fibers made from glass, carbon,and alumina, and organic fibers, such as fibers made from polyamides(nylons or aramids), polyester, aliphatic polyketones, and the like. Thefiber diameter of the reinforcing fiber can depend on the diameter ofthe plug; for example, some fibers can be within a range from 0.1 to 100μm.

Referring to FIG. 10, an alternative step of a method for making afiber-reinforced resin plug is illustrated. In some embodiments, insteadof wrapping the die 100 with a continuous filament of a fibrous material110 as illustrated in FIG. 2, a mesh 145 may be wrapped around the die100, also in a manner that applies tension to the fibers forming themesh 145. In some embodiments, the mesh 145 is a pre-preg material thatcarries a curable resin together with the mesh material. As in theembodiments described herein, the fibrous material, such as mesh 145,extends in a continuous manner from one side of the die, around oracross the rounded end, and continues on another side or location of thebody.

Referring to FIG. 11, an alternative method of making a fiber-reinforcedresin plug is illustrated. In some embodiments, multiple layers 146,148, and 150, each comprising a fibrous material and resin, may beapplied on the die 100. In some embodiments, a first layer of fibrousmaterial and resin 150 is applied, allowed to cure, a second fibrousmaterial and resin 148 is applied, allowed to cure, and then a finalexterior layer of fibrous material and resin 146 is applied and allowedto cure. Then, the individual plugs may be cut from the die 100 asdescribed above. In other embodiments, the layers are applied but arenot allowed to cure. That is, the first layer 150 is applied, the secondlayer of fibrous material and curable resin 148 is applied on top of theuncured layer 150, and then the final and exterior layer of uncuredresin and fibrous material 146 is applied on top of the middle layer offibrous material and uncured resin. Then, the three layers are allowedto cure simultaneously.

Some embodiments are related to a method of making a fiber-reinforcedresin plug 122. The method includes providing a die 100 having acylindrical body 108 terminating in a curved or rounded end 102, 104,wrapping a fibrous material 110 around the die 100 during or while thefibrous material 110 is tensioned, wherein the fibrous material 110 isplaced to extend in a continuous manner across the width of the roundedend 102, 104 of the body 108 and to opposite sides of the cylindricalbody 108, applying a curable resin 116 on the die 100, curing the resin116, and removing a reinforced cured resin plug 122 from the die 100.

In the embodiments related to the method of making a reinforced resinplug 122, the die 100 may further include a pole 106 connected to thecylindrical body 108, wherein the pole 106 extends perpendicular to alongitudinal axis of the cylindrical body 108.

In the embodiments related to the method of making a reinforced resinplug 122, removing the plug 122 includes cutting the curedfiber-reinforced resin plug 122 around the circumference of the die 100on both sides of the pole 106 to produce two reinforced resin plugs 122.

In the embodiments related to the method of making a reinforced resinplug 122, the fibrous material 110 can be applied before the curableresin 116.

In the embodiments related to the method of making a reinforced resinplug 122, the curable resin 116 can be applied before the fibrousmaterial 110.

In the embodiments related to the method of making a reinforced resinplug, the curable resin 116 and the fibrous material 110 can be appliedtogether.

In the embodiments related to the method of making a reinforced resinplug 122, the method may further include tensioning the fibrous material110 when the fibrous material 110 is applied on the die 100.

In the embodiments related to the method of making a reinforced resinplug 122, the fibrous material 110 can include spun filaments.

In the embodiments related to the method of making a reinforced resinplug 122, the fibrous material 110 can include a continuous filament.

In the embodiments related to the method of making a reinforced resinplug 122, the fibrous material 110 can be a mesh 145 of interconnectedfilaments.

In the embodiments related to the method of making a reinforced resinplug 122, the curable resin 116 can be an elastomer, such as, but notlimited to, silicone, ethylene propylene diene monomer, or rubber.

Some embodiments are related to a reinforced plug 122. The reinforcedplug 122 may include a hollow cylindrical body 130 closed by a roundedend portion 124 and open at the opposite end 128, wherein the plug 122comprises tensioned fibrous material 126 that extends in a continuousmanner across the width of the rounded end 124 and to the sides of thebody 130.

In the embodiments related to the reinforced plug 122, the fibrousmaterial 126 may include a plurality of discrete filaments, at least oneor more extending in a continuous manner across the width of the roundedend 124 and to the sides of the body 130.

In the embodiments related to the reinforced plug 122, the fibrousmaterial 110 may include a mesh 145.

In the embodiments related to the reinforced plug 122, the plug 122 mayinclude more than one layer 146, 148, 150, each layer 146, 148, 150having tensioned fibrous material 110 and resin 116.

In the embodiments related to the reinforced plug 122, the plug 122 mayinclude at least one layer 146, 148, 150 having a cured resin 116 andfurther includes the fibrous material 110 within the resin 116.

In the embodiments related to the reinforced plug 122, the plug 122 mayinclude more than one layer 146, 148, 150 of cured resin 116 and fibrousmaterial 110.

Some embodiments are related to a method for closing a conduit connectortermination 132. The method includes placing a plug 122 made from areinforced resin 116 on a conduit connector termination 132, wherein theplug 122 comprises a hollow cylindrical body 130 closed by a rounded endportion 124 and open at the opposite end 128, wherein the open end 128is placed over the conduit connecter termination 132; placing a clamp142 on the plug 122 that compresses the plug body 130 to the conduitconnecter termination 132, wherein the plug 122 comprises a tensionedfibrous material 126 that extends across the width of the rounded end124 and to the sides of the body 130 in a continuous manner.

In the embodiments related to a method for closing a conduit connectortermination 132, the pressure inside the conduit connector termination132 applies a force 138 on an inside surface of the rounded end 124 ofthe plug 122, and the force 138 is partly transferred via the fibrousmaterial 126 to a body portion 130 being compressed by the clamp 142,thereby providing for added strength.

In the embodiments related to a method for closing a conduit connectortermination 132, the conduit connector termination 132 can be a hosebarb 144.

While illustrative embodiments have been illustrated and described, itwill be appreciated that various changes can be made therein withoutdeparting from the spirit and scope of the invention.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A combination of a plugand hose connector termination, comprising: a plug having a hollowcylindrical body closed by a rounded end portion and open at theopposite end, wherein the cylindrical body and rounded end portion arecontinuously joined, wherein the plug comprises tensioned fibrousmaterial that extends in a continuous manner from one side of thecylindrical body in a lengthwise manner along the body, then across thewidth of the rounded end, and then to an opposite side of thecylindrical body in a lengthwise manner along the body; and a hoseconnector termination, wherein the plug is placed over the connectortermination and the hollow cylindrical body fits juxtaposed outside onthe hose connector termination and seals the connector termination. 2.The combination of claim 1, wherein the fibrous material comprises aplurality of discrete filaments.
 3. The combination of claim 1, whereinthe fibrous material comprises a mesh.
 4. The combination of claim 1,wherein the plug comprises more than one layer, each layer havingtensioned fibrous material and resin.
 5. The combination of claim 1,wherein the plug comprises at least one layer having a cured resin, andfurther comprises the fibrous material within the resin.
 6. Thecombination of claim 5, wherein the plug comprises more than one layerof cured resin and fibrous material.
 7. The combination of claim 1,wherein the plug is made from an elastomer.
 8. The combination of claim7, wherein the elastomer is silicone rubber, butyl rubber, ethylenepropylene rubber, ethylene propylene diene rubber, polyisoprene rubber,polybutadiene rubber, or nitrile rubber.